Packaging machine and method



July 16, 1968 J. F. BERRY 3,392,502

PACKAGING MACHINE AND METHOD Filed April 5, 1965 '7 Sheets-Sheet 1 INVENTOR. .JOHN F. BERRY w 716 5 aw ATTORNEYS July 16, 1968 J. F. BERRY PACKAGING MACHINE AND METHOD 7 Sheets-Sheet F;

Filed April 5, 1965 INVENTOR. JOHN F. BERRY %zw%4w AT TORNE YS.

July 16, 1968 .1. F. BERRY 3,392,502

PACKAGING MACHINE AND METHOD Filed April 5, 1965 7 Sheets- Sheet 4 INVENTOR. JOHN F. BERRY ATTORNEYS m DE w 9m Q J H 5 u u 9 I I I I nn. \|HII. .T Om; g i 02 s E 9 @Q n. u: s s 8 "u a v2 l um n 2 E M l: vJHW o9 r m2 w L 0: mm FhwL H wflmm 2: n2 UQ Q July 16, 1968 J. F. BERRY PACKAGING MACHINE AND METHOD Filed April 5, 196

7 Sheets- Sheet 5 1 2m oom NNN INVENTOR. JOHN F. BERRY m 6 ATTORNEYS July 16, 1968 J; F. BERRY 3,392,502

PACKAGING MACHINE AND METHOD Filed April 5, 1965 7 Sheets- Sheet 6 Fig. 11

INVENTOR. Jomv F. BERRY ATTORNEYS United States Patent 3,392,502 PACKAGING MACHINE AND METHOD John Francis Berry, Bedford, Ohio, assignor to The American Packaging Corporation Filed Apr. 5, 1965, Ser. No. 445,386 20 Claims. (Cl. 5329) ABSTRACT OF THE DISCLOSURE Cards that form display packages are stripped from a magazine above a conveyor by rotating arms that swing the card, fold it in half and deposit it upon a conveyor, where a pocket in the card is loaded. The card is moved beneath rails that close the card, then heat sealed by opposed platens and ejected.

This invention relates generally to article packaging, and more specifically to method and apparatus for heat sealing packages such as retail display packages.

The invention is particularly concerned with methods and apparatus for sealing unit display packages of the type disclosed in US. Patent No. 3,053,023. The preferred package disclosed in that patent combines the advantages of skin, blister, and shrink packaging and consists of a fold-over display card having mating product-receiving apertures in each half of the card. The product is positioned within the apertures of the double faced card so that it is snugly gripped and is covered completely by a protective pocket of plastic film such as polyethylene. With this arrangement the product may selectively project and be visible from either one or both faces of the finished package.

In forming the display packages described above, the polyethylene film is preferably adhered to the back of the card over the product-receiving apertures. Portions of the film are softened and brought through the card apertures to form pockets having the contour of the product to be packaged. After the pockets have been formed in this manner, the card is folded so that the mating pockets of each card half cooperate to define a product-contoured chamber and then the product is inserted in the chamber and the card halves secured together to complete the package.

Among the important advantages of the above described dizplay package is its simplicity and the economies which result from the product manufacturer being able to package his own merchandise without first making a very substantial investment in packaging equipment. The present invention enhances those manufacturing economies by providing equipment that packages articles at a high speed and yet is itself relatively in expensive by comparison with other high speed equipment. In addition, this equipment is Versatile, readily facilitating the packaging of articles of different sizes and the sealing of other types of packages such as blister packages. Furthermore, the invention makes it possible to complete the package with minimum handling of either the folded card or the product and in a length of time that is considerably less than with prior art equipment and techniques.

The invention contemplates feeding cards from a magazine to a conveyor. The cards are partially folded as they are fed to the conveyor. The articles to be packaged are each placed between the folded halves of a different card after the card has been fed to the conveyor. The folding is completed as the card is conveyed to a press. The card is fully closed and heat sealed in the press by a pair of heated platens. After the packages are sealed, they are automatically ejected from the packaging machine.

3,392,502 Patented July 16, 1968 ice In accordance with this invention, cards are automatically fed to a processing conveyor by a pair of rotating arms. The arms strip the cards sequentially and one at a time from a magazine above the conveyor. While the card that is engaged is swung by the arms from themagazine to the conveyor, the card is folded in half along a pre-scored line and deposited in a predetermined location on the conveyor. Articles are placed in pockets and the conveyor is moved intermittently to feed the card under two rails which substantially complete the folding. The conveyor feeds each folded card and its article between two horizontally disposed, vertically movable, heated die plates carried by press platens. During a dwell in the feed of each cycle, the platens are closed to press the two folded halves of the card together and to heat seal the package.

Movement of the transfer mechanism as well as the conveyor is accomplished by a novel positive connection gear drive transmission that provides gradual acceleration and deceleration of the transfer mechanism and conveyor as they are started and stopped in each cycle of operation. Basically, this is accomplished by a gear drive in which the drive gear is keyed to an offset portion of a driven crank shaft and drives a third gear keyed to an output shaft, via an intermediate second gear on a floating shaft. The floating shaft is mounted on links that extend both from the offset portion of the crank shaft and from the output shaft. This arrangement facilitates high speeds of operation without subjecting the components of the machine or the packages to high acceleration and deceleration forces.

One of the outstanding advantages of this construction is that each cycle has a dwell portion even though the input shaft is rotated constantly. Thus the output shaft will pause in a dwell position once each cycle while the input shaft continues to rotate. With conventional equipment of this type, a typical sealing time for packages of the type described above is from three to four seconds. With the present invention, it is possible to seal packages at the rate of between 50 and 60 packages per minute. The feed mechanism is so rapid that cards can be stripped from the magazine and fed at speeds of per minute and higher. Thus the limiting factor is the time required to effect a heat seal. As noted above, this invention is particularly useful for sealing packages of the type described in US. Patent No. 3,053,023, but many of the same advantages may be obtained when sealing other forms of display packages. Therefore, it is to be understood that the invention is not limited to the particularly disclosed package construction, which has been chosen primarily for the purpose of describing to those skilled in the tart one application in which the invention has particularly utility. Furthermore, while specific sub-combinations of the apparatus of the present invention are particularly useful in the package machine disclosed herein, it will be understood that the utility is not so limited, but that they will as well find use in other types of machines for providing similar functions.

Other features and advantages of this invention will be readily appreciated as the same become better understood by reference to the following detailed description when considered in connection with the accompanying drawings in which:

In the drawings:

FIGURE 1 is a diagrammatic, perspective, view of a packaging machine constructed in accordance with the present invention;

FIGURE 2 is a side elevational view of the machine of FIGURE 1 showing the relationship of the feeding mechanism, the conveyor, and the press and heat sealing mechanism;

FIGURE 3 is an end elevational view of the packaging machine of FIGURE 2, showing the transmission for driving the feed transfer mechanism and conveyor, and also showing the conveyor chain sprockets and the transfer mechanism, as viewed from the left end of the machine as oriented in FIGURE 2;

FIGURE 4 is a detailed end elevational view of the feed or transfer mechanism;

FIGURE 5 is a side elevational view of the feed mechanism shown in FIGURE 4 of the drawings and corresponds to the feed support bar as shown in side elevation in FIGURE 2 of the drawings;

FIGURE 6 is a side elevational view of the feed mechanism shown in FIGURE 4, showing the opposite side of the mechanism from that of FIGURE 5;

FIGURE 7 is a detailed view of a feed gear-shaft, taken along the line 7-7 of FIGURE 4 of the drawings;

FIGURE 8 is an end elevational view of the press and heat sealing mechanism of FIGURE 2 of the drawings, as viewed from the right end of the machine as oriented in FIGURE 2;

FIGURE 9 is a detailed, side elevational view, of the press mechanism shown generally in FIGURE 2 of the drawings;

FIGURE 10 is a side elevational view of the transmission for driving the feed mechanism and conveyor, viewed from the opposite side of that shown in FIGURE 2 of the drawings;

FIGURE 11 is a sectional view of the transmission of FIGURE 10, taken along the'line 11--11 of FIGURE 10, and looking in the direction of the arrows;

FIGURE 12 is a side elevational view of the transmis sion of FIGURE 10, similar to FIGURE 10 of the drawings, but showing the cams, pulleys, and linkages attached to the extending shafts of the transmission; and

FIGURE 13 is a timing and sequence diagram showing the manner in which the cams driven from the two transmissions of the apparatus control the timing and sequence of the operation.

Referring to the drawings, FIGURES 1 and 2 show a machine with a magazine 6 that carries quantity of containers. Each container is an apertured sheet of cardboard having a sheet of plastic film bonded to it. The plastic film has preformed pockets. These containers are transferred from the magazine, partially folded and deposited on a conveyor 2, which then carries the elements to a press where the package is sealed. Components making up the complete apparatus consist of a frame and housing 1, and the elongated, endless, conveyor 2, a transfer mechanism 3, a press and heat sealing mechanism 4, two transmission mechanisms 50 and 5b, and the magazine 6.

A brief general description of the entire apparatus will aid in understanding of the detailed description of specific components of the apparatus.

The frame and housing 1 support and contain the conveyor 2, the press and heat sealing mechanism 4 and the transmission mechanisms 5a, b. The frame and housing 1 supports the transfer mechanism 3 and the magazine 6 above the frame 1. A control panel 7 is conveniently located on the outside of the housing 1. A timer for the heat sealing mechanism 4 is on panel 7.

Cards 8 to be folded, filled and heat sealed are held in the magazine 6. Rollers 450 at the front of the magazine retain the upper portions of the cards. A card is individually engaged by suction cups on rotating arms of the transfer mechanism 3, which rotate 180 degrees during each cycle of operation. The arms carry a card and place it on the conveyor 2. Owing to the presence of retaining rollers 450, the upper part of the card is held back and the card is partially folded along a pre-scored line 9 as it is removed from the magazine. The card is folded during transfer to the shape shown in FIGURE 1. At this time, the conveyor and transfer mechanism stop moving. An article is placed in the lower cavity 10 of the card 8, the transfer mechanism releases the card, and the conveyor 2 advances the card forward toward the press and heat sealing mechanism 4. Curved rails 11 and .12 further close the folded card as it moves along with the conveyor.

The conveyor cycles or indexes intermittently between the loading station, one intermediate station and the pressing station. At the pressing station the folded card is fully closed, pressed and heat-sealed while the conveyor is stationary. After being heat-sealed, the card is automatically deposited in a receiving bin at the end of the apparatus.

An electric motor 12 drives the conveyor 2, and the transfer mechanism 3 through the transmission mechanism 5a, and the press mechanism 4 through the transmission 5b. The transmissions control and synchronize the movement of the transfer arms, the conveyor, and the press, provide a dwell during each cycle, and also provide gradual acceleration and deceleration of the transfer mechanism, conveyor, and press platens. Cams and limit switches, associated with the transmission mechanisms 5a and 5b operate associated clutches, brakes and appropriate control circuitry to control and assure the proper sequence of operation among the various components of the system.

Conveyor and frame Referring particularly to FIGURES 2 and 3, the frame and housing 1 is formed of spaced vertical stanchions 30, longitudinal beams 32, transverse girders 34 and base plates 35. Side plates 37 and end plates 38 fastened to the stanchions and beams form an enclosure for housing 1.

A transversely extending sprocket shaft 40 is supported in sprocket bearing support plates 42, 43 on each side of the frame and housing 1 adjacent the front corner thereof (i.e., at the upper left corner of the apparatus as shown in FIGURE 2). As best shown in FIGURE 3, a pair of spaced chain sprockets 45, 46 are fastened to the sprocket shaft 40.

A transverse chain support wheel shaft 53 extends across the top of the frame 1 at the opposite end from the sprocket shaft 40 and is supported by a wheel shaft support bar 55 on each side of the frame. A chain support wheel is mounted adjacent each end of the shaft 53. A second chain support shaft 58 is supported in the same wheel shaft support bars directly beneath the first chain support wheel shaft 53. A pair of transversely spaced chain support wheels 59 are mounted on shaft 58.

A pair of endless chains 63 and 64 are carried about each set of chain sprockets and chain support wheels. The chains extend longitudinally along the frame and housing 1 adjacent each side thereof. The upper reach of each chain is supported upon an upper chain support bar 68 and the lower reach of each chain is supported by a lower chain support bar 70. The chain support bars are fastened to studs on the side frame elements of the apparatus. Just above the center of the lower reach of each chain 63, 64, is a transversely extending shaft 72. A pair of spaced center guide wheels 74 are mounted for rotation on the shaft 72 and engage the upper surface of the lower reach of each chain. The shaft 72 is mounted in suitable bearing plates 75 fastened to the frame.

Card supporting trays 71 (FIGURE 1) are fastened between the chains 63 and 64 and carried by transverse bars 73, which are secured by screws (not shown) to small brackets 73a, 7311 on the chains 63, 64, respectively. The trays are formed of a flexible material, such as Mylar or thin tempered metal and are open, except for small corner tabs that support the cards, in the central area underlying the cards to be sealed. Upstanding guides 76 extend above the top surface of the trays 73 to properly locate a card over the opening. The opening allows the pressing and heating sealing dies of the press mechanism 4 to come in direct contact with the card.

A plurality of base plates are secured to the lower portion of the frame and housing 1. These include a base plate 77 that supports the transmission mechanism 5a, a base plate 78 that supports the drive unit 12, and a base plate 80 that supports the press and heat-sealing mechanism 4, including the transmission 512.

A feed support bracket 84, 85 is mounted on each longitudinally extending side of the frame and housing 1, adjacent the chains sprockets 45 and 46. The brackets 84, 85 are fastened directly to an upper longitudinally extending beam or frame bar 83. Each feed support bracket 84, 85 supports an upstanding feed support bar 86, 87, respectively, of the transfer mechanism 3.

A pulley wheel 88 is fastened to one end of the sprocket shaft 40' and is driven by a timing belt 90 from the transmission mechanism 5a. Rotation of the pulley wheel 88 drives the two chain sprockets 45 and 46 in an intermittent manner, to be described subsequently. This in turn drives the two chains 63 and 64 to advance the packaging supportingtrays 73 through a plurality of stations along the upper reach of the chains, along the frame and housing 1.

Transfer mechanism The transfer mechanism consists of two angularly disposed, upstanding, support bars 86 and 87, spaced from each other transversely of the frame and housing 1. A mounting bar or feeder bar 95 extends transversely between upper ends of the spaced support bars 86 and 87 and supports a pair of parallel feeder arms 149, 150. The feeder bar 95 has stub shafts 96 and 97 extending from opposite ends, journaled for rotation within the feed support bars 86 and 87, respectively. A pulley wheel '98 is fastened to the end of the feeder bar 95 adjacent the feed support bar 86 by machine screws 99. A feed pulley 101 is supported on a feed pulley lower stud 183 at the lower end of the feed support bar 86, and a timing belt 104 connects the feed pulley 181 with the pulley wheel 98. A second timing belt 106 also encircles the lower feed pulley 101 and is connected to a drive pulley of the transmission mechanism.

The feed support bar 87 has two vertically spaced shift ring bearing blocks adjacent the upper end, one above and one below the feeder 'bar 95. As better shown in FIGURE 6, a shift ring 115 is supported between the upper and lower shift ring bearing blocks 110 and 111, and is mounted for pivotal movement about a vertical axis on an upper stub shaft 116 and a shift rod 118 that is supported along feed support bar 87. The shift rod 118 is mounted in the shift ring bearing block 111 and in vertically spaced shift rod bearing blocks 120, 121 at the lower end of the feed support bar 87. The shift rod is formed of two portions keyed together so that the upper portion may be extended or shortened relative to the lower portion to permit the length to be varied as the support bars are adjusted vertically for different size cards.

A shift rod lever 125 extends at right angles from the lower portion of the shift rod 118, between the two, spaced, lower shift rod bearing blocks 120 and 121. A feed-shift link stud 127 extends from the shift rod lever and is connected with an upper feed-shift link 1130, which is connected via a linkage to be subsequently described, to the transmission mechanism 5a.

The shift ring 115 encircles an end portion of the feeder bar 95, adjacent the feed support bar 87. A pair of shift ring roller blocks 133 and 134 are fastened to the shift ring 115, on opposite sides and at diametrically opposed positions about the circumference, displaced 90 degrees from the upper stub shaft 116 and shift rod 118. Two shift ring rollers 135, 136 are provided, one being suitably mounted for rotation 'by each shift ring roller block.

A feed shift rack 148 is mounted on the feeder bar 95 for longitudinal, sliding, motion along the bar transversely of the frame and housing. The rack 140' is formed with two elongated central openings 141, 142. Rack teeth 143, 144 are formed on one inside edge of each opening, but on an opposite side of each. As shown in FIGURE 4, the teeth of the rack adjacent the feed support bar 87 are on the lower inwardly facing surface or edge and the teeth of the rack adjacent the feed support bar 86 are in the upper inwardly facing surface of the rack. An abutment 145 extends at right angle from the shift rack 140 at the end adjacent the shift ring. The abutment is positioned to be located opposite one of the shift ring rollers 135, 136 when the feeder bar is in the position shown in FIGURE 2, i.e., when the feeder or transfer mechanism is in position to engage a card from the magazine 6. Pivotal movement of the shift ring causes one of the rollers 135, 136 to engage the abutment 145 and shift the rack longitudinally relative to the feeder bar 95. Upon 180 degrees of rotation of the feeder bar, pivotal movement of the shift ring 115 causes the other of rollers 135, 136 to engage the opposite side of the abutment and shift the rack in the opposite direction. A spring biased detent 148 holds the rack in either shifted location.

A pair of spur gear segments 1 46 and 147 are mounted in the feeder bar 95 and are positioned within the elongated open portions 141, 142 of the feed shift rack 140. The gear segments 146 and 147 mesh with the teeth 143 and 144, respectively, of the feed shift rack 140. With this arrangement, movement of the rack in one direction simultaneously rotates the gear segments 146, 147 in opposite directions.

Each gear segment 146 and 147 is fastened to a feed gear-shaft or feeder arm 149 and 150, respectively. The feed gear-shafts 149 and 150 are supported by gear-shaft support blocks 152, 153. These blocks are in turn supported by the feeder bar 95 and may be adjusted longitudinally along the feeder bar, being held in proper position by clamp block's and 156, respectively. With this arrangement, the spacing between the feed gear-shafts 149 and 150 may be adjusted to facilitate different sizes of cards, as will be apparent from the subsequent disclosure. The shafts 149, 150 are constructed of telescoping sections so the length may be conveniently adjusted. The shafts each extend transversely of the feeder or rotatable mounting bar 95 in two diametrically opposite directions.

As best shown in FIGURES 2 and 7, a support rod in the form of a vacuum tube 158 is" supported at each end of each feed gear-shaft 149, 150. The tubes at the opposite ends of each feed gear-shaft are perpendicular to the longitudinal axis of the shaft and extend in direction displaced from each other by 90 degrees. The tubes on either feed gear-shaft are oriented relative to the tubes on the other so that when the upper or lower tubes of each extend toward the other, the tubes at the opposite ends are parallel. As shown in FIGURE 2, a vacuum tube 158a is in an upper portion and is oriented generally parallel to the extent of the conveyor chains 63 and 64 and also parallel to the magazine 6 above the conveyor. At the same time, a lower vacuum tube 158b extends transversely and inwardly of the frame and housing. A vacuum cup 160 is fastened to the end of each support rod or vacuum tube 158. The vacuum cup serves to engage a sheet or card to be transferred from the magazine 6. The work engaging face of each suction cup 160 is oriented in a plane parallel with planes passing through the longitudinal axes of both the respective feed gear-shaft and the respective vacuum tube, and faces the front card 8 in the magazine 6 when in the upper, transversely extending position. As will be apparent from FIGURES 4 and 7, movement of the feed shift rack 140 by shift ring 115 rotates the gear segments 146, 147. These in turn rotate the feed gearsh afts 149, 150, and hence the vacuum tubes 158 and associated suction cups 160, about the longitudinal axis of the feed gear-shaft.

Two feeder bar vacuum tubes 170, 171 extend along opposite sides of the feeder bar 95 and open through the end adjacent feed support bar 86. Each vacuum tube 170, 171 opens through the pulley 98 at diametrically opposed locations. Two outlets 172, 173 extend from tube and two outlets 174, 175 extend from tube 171. Each of these is connected with a tube 176 (FIGURES 2 and 7) to a vacuum tube at the end of each feed gear-shaft 149,

150. A vacuum control plate 177 is located at the upper end of the feed support bar 86. The plate has an arcuate channel 178 in the form of a semi-circle that extends generally along the path followed by the openings of vacuum tubes 170, 171. The channel 178 communicates to the tubes 170, 171 through an arcuate opening in a bearing 179 for the pulley 98. A passageway 180 communicates through the vacuum control plate 177 to the channel 178 and is connected to a source of vacuum. A small bleed hole 181 is formed in the vacuum control plate 177 adjacent one end of the channel 178. With this arrangement, one of the tubes 170, 171 is in communication with the channel 178 as the feeder bar 95 rotates. The location of channel 178 is such that this supplies vacuum to the vacuum cups of the feed gear shafts on arms 149, 150 that are in position to engage and carry a card from the magazine 6 to the conveyor. When the feed gear shafts reach the position where the card is deposited on the conveyor, the open end of the tube 170 or 171 passes beyond the channel 178 to bleed hole 181 and the vacuum is broken. At the same time, the open end of the other tube 170 or 171 is brought into communication with the other end of the arcuate channel 178 and will remain in direct communication therewith until the feeder bar 95 again rotates 180 degrees.

Vertical adjustment of the feed support bars 86 and 87 is facilitated by a rack portion 186 formed part way along one edge thereof, as best shown in FIGURE 5. A feed raise shaft 188 is supported in the feed support brackets 84, 85, and extends between the feed support bars 86 and 87, adjacent the rack portions 186 thereof. Spur gears 190 and 191 are fastened to the feed raise shaft 188, one in meshing relationship with each rack portion 186 of the feed support bars. A support bar clamp pad 194 is mounted in each of the feed support brackets adjacent an edge of the feed support bar, on the opposite side from the rack portion 186. With this arrangement, rotation of the feed raise shaft 188, as by a hand key or crank, raises the feed support bars 86 and 87 by the engagement of the spur gears 190, 191 with the rack portions 186. The support bar clamp pads 194 thereafter retain the feed support bars in the desired position. Thus, the feed support bars may be raised or lowered to facilitate different sizes of the packaging cards and, of course, the feed gear shafts 149 and 150, by virtue of their telescoping arrangement, may be adjusted accordingly. The pulleys 98, 101 and belt 106 move with the feed support bar 86.

As shown in FIGURE 2, the magazine 6 is at an angle of degrees with respect to the conveyor. The feed support bars 86 are at an angle of 18 degrees from the vertical. With this arrangement, an adjustment in the height or effective length of the feed support bars 86 may be made to accommodate different sizes of cards while yet not changing the location of the center of the card surface when it is placed on the conveyor. Therefore, there is no necessity with this arrangement to adjust the cycling of the conveyor for different sizes of cards to be fed to the machine.

With the feed gear shafts and suctions cups in the posi'ion shown in FIGURE 2, movement of the upper feed shift link 130 rotates the shift rod lever 125 and the shift rod 118 to pivot the shift ring 115. This moves the feed shift rank 140 to rotate the feed gear shafts degrees. This causes the vacuum cups 160 that are in the upper position as shown in FIGURE 1 to engage with a card 8 to be fed from the magazine. While the upper suction cups are rotated 90 degrees into contact with the card to be fed, the lower suction cups are rotated 90 degrees into a position 'where they will clear the magazine as they are rotated from the level of the conveyor to the level of the magazine. The feeder bar then rotates 180 degrees during a cycle to feed a card from the magazine to the conveyor. During rotation, vacuum is supplied to the upper vacuum cups and is cut off from the lower vacuum cups by virtue of the relationship between the vacuum control plate 177 and the inlet apertures to the feeder bar vacuum tubes 170, 171. During the subsequent cycle, the upper feed shift link will again rotate the shift ring. The feeder bar at this time is upside down and the opposite feed shift ring roller engages the cam surface of the feed shift rack shifting it in the opposite direction to rotate what were the lower suction cups, but which are now the upper suction cups, into Work engaging contact with the packaging elements of the magazine. The feeder bar 95 is then again rotated degrees as another cycle is performed. The overall operation of this feeder mechanism in conjunction with the complete operation of the apparatus will be described in more detail subsequently.

Press and heat sealing mechanism The press and heat sealing mechanism 4 is supported on the base plate 80 of the frame and housing 1. See FIGURE 2. The press mechanism is generally housed wi.hin side base plates 200, side plates 282, and a top tie plate 204. A pair of vertical, transversely spaced, longitudinally extending, crank plates 206 and 207 are supported on the base plate 80. Three crank shafts 210, 211 and 212 extend in a horizontal plane transversely across the frame and housing 1 between the two crank plates and are supported for rotation by the plates. The front crank shaft 210 and the rear crank shaft 212 each have a crank stud at each end of the crank shaft outside the supporting crank plates. One of these studs of each shaft 210 and 212 is shown at 214 and 215, respectively. Each crank stud of each shaft supports the lower end of one of a pair of lower connecting rods that cooperate with each shaft, one at each end thereof. One of each pair of connecting rods is shown at 217 and 218. The upper end of each lower connecting rod of the pairs 217 and 218 supports a lower platen 225 by platen studs 222 and 223, respectively, fastened to a lower platen 225. A lower plate heater 226 is supported on the lower platen. A lower die plate 227 formed to press the card 8 is supported above the lower plate heater 226.

A crank stud 228 extends from each end of the center crank shaft 211. The lower end of each of a pair of upper connecting rods 230 is connected to the center crank shaft 211 by these studs. The upper end of each of the upper connecting rods 230 supports an upper platen 235 by platen studs 232 fastened to the upper platen. An upper plate heater 236 is fastened to the lower surface of the upper platen 235, and an upper die plate 237 is supported below the upper plate heater 236. Both the upper plate heater 236 and the lower plate heater 226 are connected by platen wires to a source of electric current used by the heaters to generate heat.

A lower platen guide 239 is fastened to a side plate stiffener 244) on each side of the mechanism 4 and receives a rod guide extension from the adjacent platen stud 223. Similar upper platen guides 242 are supported on each lateral side of the upper platen 235 on the side plates 2G2 and receive a rod guide extension of each upper platen stud 232.

The lower and upper die plates 227 and 237 are each formed with a base of a size corresponding to the plate heaters. Each being a mirror image of the other, only the lower die will be described. The die plate 227 has an upward projecting protion 244 corresponding in size to the folded card 8. Centrally of the projecting portion 244 is a recessed opening 246 constructed to receive the pocket of the card in which the article being packaged is located.

A transmission 5b is provided to transmit power from the electric motor 12 to the press. The internal gearing of the transmission 51) is essentially the same as the construction of the transmission 5a, which will be described in detail subsequently. Both of these transmissions are capable of providing an intermittent rotational output from a constant rotation input, and both provide gradual acceleration and deceleration in conjunction with a dwell period during each cycle. The principal difference between the transmission b and the transmission 5a is that the transmission 5b for driving the press unit incorporates a gearing arrangement that provides a relatively short dwell period. For present purposes, therefore, the description of the transmission 512 will be limited to a description of the input and output features and their cooperation with the mechanisms of the press itself.

The transmission 5b is driven by a timing belt 250 from an electric motor 12 to a pulley 252 connected to a power input shaft 253 on the transmission 5b. A magnetic clutch and brake are connected by the input shaft.

A power output shaft 255 rotates a pinion gear 257. The pinion gear 257 directly engages a gear 259 fixed to the center crank shaft 211. The relationship of the pinion gear 257 and the crank shaft gear 259 is such that one revolution of the pinion gear provides one half of a revolu tion of the crank shaft gear 259. A crank shaft gear 300 is fixed to the front crank shaft 210 and a crank shaft gear 302 is fixed to the rear crank shaft 212, both being of equal size to crank shaft gear 259 and each meshing therewith. By virtue of this construction, during each cycle of operation where the output pinion gear 257 rotates once, the crank shafts 210, 211, 212 will rotate through 180 degrees to move the upper and lower platens 235 and 225 from an open position to a closed position and will then open the platens during a subsequent cycle.

Two cam shafts 305 and 306 are associated with the transmission 5b. Cam shaft 305 is an extension of a shaft of the transmission 5b that is driven at a constant speed off of the input shaft through suitable gearing. The shaft 305 rotates one revolution for each cycle. A cam 308 fixed to cam shaft 305 operates a limit switch LS6 to deenergize the electric clutch of the transmission 5b to stop the operation of the press once during each cycle, that is, each time the platens are in closed position or open position.

Two cams 340 and 341 are fixed to cam shaft 306. The cam shaft 306 is driven from the crank shaft 212 through gear 342 on crank shaft 212 and gear 343 on cam shaft 306, both of which are of equal pitch diameter. The cam shaft 306 therefore rotates one half revolution along with the crank shaft 212 during each cycle. The cam 340' actuates a limit switch LS1 and the cam 341 operates a limit switch LS3. Limit switch LS1 controls what is essentially an interlock that prevents energization of the feeding mechanism if the platens are closed, and limit switch LS3 actuates a timer that controls the duration of the pressing operation. A more complete explanation of the operational sequence will be set forth subsequently. It will be seen that, with the construction described, the upper and lower platens 232 and 225 are supported by the associated connecting rods carried by crank shafts 210, 211, 212. As shown in FIGURES 2 and 9, the upper connecting rods are in their highest position when the lower connecting rods are in their lowest position. Rotation of the crank shafts therefore simultaneously lower the upper platen and raise the lower platen to press a folded and filled display card between die plates carried by the platens. The upper and lower plate heaters apply heat to the die plates, which are in direct contact with the folded card and which therefore heat seal the folded card under pressure and heat. When the crank shafts are rotated another 180 degrees after the heat sealing step has been finished, the platens opened and the conveyor is advanced to remove the sealed card and to introduce a new card to be sealed.

Feed transmission mechanism The feed transmission 5a is best shown in FIGURES 2, 3, 10, 11, and 12. A housing 350 is provided having apertured side walls 351 and 352 and an intermediate wall 353 (FIGURE 11) that support a plurality of horizontally disposed transmission shafts.

A power input shaft 356 is journaled in suitable bearings 357, 359 in an upper corner of the housing 350. A crank shaft 358 is journaled in axially aligned apertures in the side walls 351, 352 and the intermediate wall 353 for rotation about the axis of the journals. The crank shaft 358 extends beyond the side walls of the outer housing on each side. An output shaft 360 is also journaled in the side walls 351, 352 and the intermediate wall 353 above the crank shaft 358, and also extends beyond the side walls of the outer housing on each side.

As best shown in FIGURES 2 and 12, a drive pulley wheel 362 is fixed to the power input shaft 356. The pulley is driven by a timing belt 363 from the electric motor 79. A belt tightening wheel 364 is biased against the outer surface of the lower reach of the timing belt 363 to maintain proper tension. An output pulley 366 is fixed to the output shaft 360 on the same side of the transmission housing as the drive pulley wheel; i.e., adjacent side wall 351. The output pulley 366 is driven via a ratchet type, spring release, clutch 368 (see FIGURE 3) allowing the power output shaft to override the output pulley 366 in the event the mechanism driven by the output pulley should become jammed. A similar clutch is provided on the other end of the shaft. A pair of limit switches LS7 and LS8 are mounted on the transmission housing to be actuated by the clutches in the event the transmission overrides the associated output pulleys and driven mechanisms, to tie-activate the machine. The output pulley 366 drives the timing belt that operates the chain conveyor mechanisrn 2.

A gear train consisting of a first gear 370 fastened to the opposite end of the output shaft 360, adjacent the side wall 352, and a driven gear 371 mounted on a shaft 372, is also driven by the output shaft 360. The gears 370 and 371 are of equal diameter and serve to reverse the rotation of the output shaft 360 and provide for adjustment of the feed mechanism. The shaft 372 is supported by a feed pulley bracket 374 fastened to an extension bracket 375 mounted to the frame of the machine. A mounting bolt 377 and clamp washer 378 mount the feed pulley bracket 374 for angular adjustment about the extension bracket 375. This allows the shaft 372 to be pivoted about the axis of the mounting bolt. A pulley 380 is secured to the opposite end of the shaft 372 from the driven gear 371. The pulley 380 drives the timing belt 106 that is connected with the feed pulley 101 carried at the lower end of the feed support bar 86 of the transfer or feeding mechanism.

A machine screw 384 is attached to the feed pulley bracket 374 and is connected by a spring 385 to a supporting bracket. With this arrangement, the feed pulley bracket 374 may be pivoted about the mounting bolt 377 when the feed support bars 86 and 87 are moved up or down to accommodate a different size card. Thus, uniform tension can be maintained on the timing belt 382. When this is done, a mounting bolt 386 and clamping washer 387 holding the pulley 380 on the shaft 372 are loosened so that vertical adjustment of the feed support bars does not rotate the pulley 380 to change the relative position of the feeder bar and feed arms with respect to the magazine 6.

A plurality of cams are driven from the extending ends of the crank shaft 358. A cam extension shaft 390 extends from the end of crank shaft 358 adjacent side wall 352, on the same side of the transmission as the feed pulley 380. Three cams 391, 392, 393 are carried by the extension shaft 390 and control the sequence of operation of the mechanism, as will be described subsequently. These cams co-operate with the limit switches LS5, LS2 and LS4, respectively.

A feed shift cam 395 is provided on the opposite end of the crank shaft 358, as more clearly shown in FIGURE 12. A feed cam lever shaft 397 is mounted beneath and to one side of the feed shift cam. A generally horizontally extending feed-shift cam lever 400 is pivoted about the feed cam lever shaft 397. A cam follower roller 401 is attached to the distal end. A stroke adjustment lever 403 is also fastened to the feed cam lever shaft 397 and extends generally upward. The stroke adjustment lever 403 is fastened to the lever shaft in fixed relationship with respect to the feed shift cam lever so that the feed shift cam lever and the stroke adjustment lever co-operate in the manner of a bell crank. The stroke adjustment lever 403 is attached at the distal end to a lower feed shift link 404. This in turn is connected via a feed shift intermediate lever 406 (see FIGURE 2) to the upper feed shift link 130. It will be now apparent that rotation of the feed shift cam 395 oscillates the upper feed shift link 130 to in turn oscillate the shift ring 115 to shift the rack 140 of the feeder bar 95.

Reference is now made to FIGURES l and 11 showing the gearing within the transmission 5a. As shown, a magnetic clutch 410 is mounted on the inner end of the input shaft 356. The magnetic clutch 410 drives an aligned shaft 412 suitably journaled in the side wall 352 and the intermediate wall 353. One end of the shaft 412 extends beyond the side wall 352. A magnetic brake 414 is mounted on the side wall 352 and operates in the extending portion of the shaft 412 to control the rotation.

A pinion 416 is keyed to the shaft 412 and drives the crank shaft 358 through a reduction gear train. The train consists of a gear 417 on a shaft 418, pinion 419 fixed to the shaft 418, meshing with a gear 420 keyed to the crank shaft 358.

The crank shaft 358 includes an offset or crank portion indicated at 422. A circular spur gear 424 is keyed to the offset portion 422 of the crank shaft 358.

A pair of links 426, 427 are each mounted at one end by suitable bearings on the offset portion 422 of the crank shaft 358, one on each side of the spur gear 424. A shaft 429 is mounted for free rotation between the links 426, 427, at the other ends. A floating gear 430 is supported on and freely rotatable about the shaft 429, and is held in meshing relationship with the spur gear 424 by the links 426, 427.

Ends of the shaft 429 extend through and beyond the outer surfaces of the two links 426, 427 and receive the ends of two additional links 433, 434, which are each fastened to the shaft 429 by a nut. The other ends of the links 433, 434 are on the output shaft 360 with suitable bearings that allow free rotation of the links about the shaft. A spur gear 436 is keyed to the output shaft 360 between the two links 433, 434.

The mode of operation of the transmission gearing will be best understood in conjunction with FIGURE 10. The gears are shown in FIGURE with the shortest radius of the eccentrically mounted gear 424 in meshing contact with the floating gear 430. When these two gears are in this relationship, the floating gear 430 is at its lowest position with respect to spur gear 436 on the output shaft 360 as the transmission is oriented in FIGURE 10.

The eccentric or crank shaft 358 is rotated at a constant speed by the input shaft 356 and the reduction gearing already described. For purposes of illustration, consider rotation of the spur gear 424 on the crank shaft 358 in a clockwise direction as shown in FIGURE 10. The effective radius of the gear 424 is at its minimum. Rotation of the crank shaft 358 at a constant speed causes the spur gear 424 to rotate and orbit in the path indicated by the dotted line in FIGURE 10 about the axis of the crank shaft journals. The rotational movement of the spur gear 424 causes rotational movement of the floating gear 430. At the same time, the rotation of the crank shaft 358 causes the links 426, 427 to be displaced essentially longitudinally, in a manner analogous to that of a piston rod on a crank shaft of a motor. This movement is of course influenced by the links 433, 434 attached to output shaft 360 and, as a result, the floating gear 430 travels in an arcuate path about the axis of the spur gear 436 on the 12 output shaft. This path is shown in dotted lines in FIG- URE 10.

It will be apparent from the direction of rotation of the floating gear, as shown by the curved arrow in FIGURE 10, that the movement of the floating gear in the arcuate path around the spur gear 436 will change the rate at which the rotation of the floating gear is transmitted to the spur gear 436.

Referring back now to the eccentrically mounted spur gear 424, clockwise rotation from the position shown in FIGURE 10 will cause the floating gear to rotate counterclockwise about the axis of the floating shaft 429 at a gradually increasing speed as the effective radius of the spur gear 424 at the point of meshing gradually increases to the maximum point after 180 degrees of rotation. During this rotation, the floating gear will be driven counterclockwise in the arcuate path around the output spur gear 436. Since the output spur gear is being driven in a clockwise direction by the rotation of the floating gear about its own axis, this counterclockwise movement of the floating gear in the arcuate path diminishes the speed at which the output gear is driven. At the beginning of each cycle, when the peripheral speed of the eccentric gear at the point of meshing is low and therefore the rotational speed imparted to the floating gear is low, the rate of movement of the floating gear about the spur gear 436 is relatively great because the effective radius of the eccentric gear is increasing rapidly and thereby forcing the floating gear at the same rate around the spur gear 436.

As the eccentric gear approaches mid-rotation, i.e., after 180 degrees of rotation from the position as shown in FIGURE 10, the rotational speed transmitted to the floating gear is high whereas the rate of movement along the arcuate path about the gear 436 is relatively low for a given degree of rotation of the eccentric gear.

With this arrangement, gear diameters and a degree of eccentricity of the gear 424 may be chosen so that the rate at which the effective radius of the eccentric gear changes will move the floating gear about the gear 436 at a variable speed that exactly balances the rotational acceleration of the floating gear during a part of the rotational cycle of the eccentric gear. That is, the floating gear walks around the output gear 436 due to the movement of the links 426, 427 at the same rate (i.e., the same number of teeth per unit time), as it is being driven in rotation by the eccentric gear 424. While this condition exists, the output gear 436 on output shaft 360 will not be rotated. Thus, with this gear arrangement, a dwell may be provided with respect to the output shaft while the input shaft is rotated at a constant speed. Furthermore, between the dwell period that occurs once each cycle, the rotation of the output gear is accelerated and decelerated at a gradual rate.

Depending upon the relationship between the gear diameters and the eccentricity of the driving gear, the dwell may be varied to maintain the gear 436 essentially stationary during a total of up to degrees of rotation of the eccentric gear, or about 20% of the cycle.

By way of one specific example of the functioning of the transmission gearing above described, the input shaft 356 is rotated at a constant speed and, through the reduction gearing, drives the eccentric shaft 358 one revolution for each 14 revolutions of the input shaft. The spur gears 424 and 436 both have pitch diameters of 1.667 inches. The floating gear 430 has a pitch diameter of 2.33 inches. The crank shaft 358 is fixed in the transmission housing a distance of 2.50 inches from the output shaft 360, center to center. The distance of the center of the spur gear 424 to the center of the crank shaft axis 358 (i.e., the distance of eccentricity) is 0.634 inch. This arrangement provides a dwell period of the output shaft 360 during 70 degrees of the rotation of the eccentric or crank shaft 358. Thus, it can be seen, that with an eccentric circular gear and a circular output gear both of equal pitch diameter, a floating gear of 1.4 times the diameter of the eccentric and output gears, and a distance of eccentricity of 38% of the pitch diameter of the eccentrically mounted gear, a dwell period is produced in the output shaft during approximately 20% of the input cycle.

In the specific example above described, the dwell period may be varied by changing the distance of eccentricity. A distance of eccentricity of 0.550 inch produces a momentary dwell while a distance of eccentricity of 0.634 inch provides a dwell during 70 degrees of the rotation of the crank shaft or eccentric shaft. Thus, a dwell will be produced, where the eccentric gear and the driven output gear are of the same pitch diameter, the floating gear is of a diameter of 1.4 times the pitch diameter of the eccentric gear and output gear, and the driving gear is eccentric by a distance equal to between 33% and 38% of the pitch diameter of the eccentric gear.

In the transmission a used to drive the conveyor belt and feeder mechanism, a dwell period is provided during 70 degrees of rotation of the eccentric shaft, i.e., during about 20% of the cycle. In the transmission 5b operating the press unit, a dwell is provided during approximately 5 degrees of rotation of the eccentric shaft. As will be explained in more detail subsequently, these dwell periods do not account for the full dwell period of the overall machine operation. Rather, the transmissions are disengaged during each cycle. The arrangement does facilitate the gradual acceleration and deceleration of conveyor, feed mechanism, and press unit during the intermittent operation required by the machine. Furthermore, the dwell period allows for slight error in timing when the magnetic clutch that couples the input shaft of each transmission to the gear drive is actuating or deactuated. Thus, a clutch energized or de-energized at the beginning or at the end of each cycle, if actuated during a dwell period, will not affect the relationship between any of the driven mechanical elements.

Operation The overall operation of the packaging machine above described will be best understood with respect to the timing diagram of FIGURE 13.

As previously described, cams 340, 341 and 308 are associated with the transmission 5b of the press. Cams 392, 393, and 391 are associated with transmission 5a of the conveyor and feeder.

Cam 391 closes the limit switch LS5 immediately after the start of a revolution of the eccentric shaft of the transmission 5a and stops the transmission at the end of a cycle, after one revolution.

Cams 392 opens a limit switch LS2 to set up a'condition in a control circuit to switch from energization of the magnetic feed clutch 410 in the transmission 5a to the corresponding clutch in the transmission 5b to operate the press at a proper time.

Cam 393 closes a limit switch to start the press from an open position to a closed position by energizing the press transmission 5b, i.e., by energizing a magnetic clutch of the transmission 5b arranged as described in the transmission 5a.

Cams 340 and 341 revolve 180 degrees during each cycle of operation. Cam 340 actuates limit switch LS1, which functions as an interlock, and thereby prevents the conveyor and feeder from being started while the platens of the press mechanism are closed. When limit switch LS1 is closed by cam 340, the feed mechanism begins operation. Cam 341 actuates the limit switch LS3 to start a timer just prior to the complete closing of the press. The cam 341 also resets the timer after the timer has timed out. This is the timer 20 on panel 7.

The cam 398 actuates the limit switch LS6, which stops the transmission 5b when the presses have reached the closed position or opened position at the end of a cycle.

It will be apparent that, because the transmission mechanism provides a short dwell period during which time the output shaft from which the presses are driven is stationary, a slight delay in the actation or operation of the brake of the transmission which would otherwise means that the press might not be stopped in exactly the closed position, is not critical.

The operation sequence is as follows:

Initially, the motor 12 is started with a motor switch of an overall typical relay control circuit. Heater switches are turned on to apply current to the plate heaters of the upper and lower platens. The temperature of the plate heaters is thermostatically controlled. With the machine on automatic operation, an operator presses a foot switch to start the machine.

For convenience, it will be assumed that the machine is in operation at the point in the cycle indicated by the second vertical line from the left in FIGURE 13, where the feed rack shift begins.

As will be apparent from the legend on the drawings, the platens are opening. Transmission 5b is operating, transmission 5a is not. The cam 340 now closes LS1, starting transmission 5a by actuating magnetic clutch 410. This rotates cams 392, 393 and 391 and feed shift cam 395. The gearing is at a d'well portion of the cycle and hence the conveyor 2 and feed mechanism 3 remain stationary. One pair of feed-gear shafts are adjacent a card in the magazine 6.

The feed shift cam 395 shifts the feed rack through the feed shift cam lever and associated linkage. This brings vacuum cups into contact with a card to be fed.

Cam 391 close limit switch LS5 immediately at the beginning of the cycle and operation of the transmission 5a, allowing the transmission to operate. Shortly thereafter, cam 392 opens limit switch LS2 to prepare the control circuit for the subsequent energization of the clutch of the transmission 5b of the press mechanism. Cam 393 is, of course, rotating, but has no effect at this time.

After the shift of the feed rack, due to oscillation of the shift ring 115 by the feed shift cam 395, the feeder bar is driven from the output shaft 360 of the transmission 5a, via the pulleys and timing belts already described Vacuum is supplied to the cups 160, to carry the contacted card, through the vacuum control plate. At the same time, the output pulley 366 on the other side of the transmission 5a drives the spocket shaft 40 and the conveyor 2. The delay in the starting of the transfer mechanism and conveyor after the operation of the feed shift cam 395 is due to the dwell period produced by the transmission drive. That is, the feed shift cam 395 is driven off the constantly rotated eccentric shaft while the transfer mechanism and feed conveyor are driven off the output shaft of the transmission that provides a dwell as well as gradual acceleration and deceleration.

After the transfer mechanism and conveyor begin moving to feed a card from a magazine 6 to the conveyor, and to feed a previously folded and loaded card to the press, the platens of the press reach an open position, at which time the cam 308 closes limit switch LS6 to stop the transmission 5b driving the press.

The press remains open while the card from the magazine is being fed and folded to the conveyor, and while an already and folded card from an intermediate station between the loading and pressing station is moved into the press.

As a card is placed by the feed gear shafts and associated suction cups upon a tray of the conveyor, the gearing of the transmission slows both the transfer mechanism and the conveyor to a gradual stop. At the same time, the inlet to the appropriate feeder bar vacuum tube has passed beyond the channel 178 in the vacuum control plate 177 and overlies the bleed hole 181, thereby releasing the vacuum in the vacuum cup holding the card.

Just as the transmission reaches the dwell period and the transfer mechanism and conveyor come to a gradual stop, cam 393 actuates limit switch LS4 to engage the magnetic clutch of the press transm-isison 5b, thereby starting the press closing. Before the press completely closes, the transmission 5a reaches a dwell of the cycle, thereby stopping the feed mechanism and conveyor. At this time,

cam 391 opens switch LS5 to disengage the magnetic clutch of the transmission 5a and to engage the magnetic brake, thereby stopping the operation of the transmission 5a and ending a cycle.

The beginning of the operation of the transmission 5b of the press mechanism is shown by the fourth vertical line from the left in FIGURE 13, indicating that portion of the cycle where the presses begin to close. As cam 340 begins to turn, it actuates limit switch LS1, which prevents the transfer mechanism and conveyor from being operated while the presses are closed.

After the platens of the press are almost closed, cam 341 actuates limit switch LS3 to start a timer that times the pressing and heat sealing operation. Very shortly after the timer begins operation, the platens of the press reach a fully closed position and the cam 308 actuates limit switch LS6 to stop the transmission 5b.

When the timer times out, it starts the transmission 5b and is immediately reset by further rotation of cam 341, in preparation for the next cycle.

As the transmission starts again, it opens the platens of the press mechanism. After the presses begin opening, cam 340 actuates limit switch LS1 to start the transmission 5a, to begin another feed transfer and conveying cycle. When the press completely opens, cam 308 agains actuates limit switch LS6 to stop the transmission 5b that operates the press.

In terms of the functional sequence of operation, it will be understood that the stack of cards is held in the magazine 6 above the conveyor 2 of the apparatus. Each card is prescored along a horizontal line across the middle of the card. When the feed gear shafts that are in the upper position are rotated about their longitudianl axes 90 degress by the feed shift cam 395 and the feed shift rack 140, the vacuum cups at the upper ends of the feed gearshafts rotate into contact with the outermost card of the magazine. The card is oriented with the outside surface facing the vacuum cups. The vacuum cups engage the outer surface just beneath the prescored horizontal line and rotate counter clockwise in the orientation shown in FIG- URE 2 of the drawings. Because the upper portion of the card is retarded by retaining rollers reference numeral 450 at the top of the magazine, as shown in FIGURE 1 of the drawings, only the lower part of the card moves initially, thereby tending to fold about the prescored line. The bottom half of the card engaged by the vacuum cups is rotated through 180 degrees along with the feed gear-shaft as the feeder bar 95 is rotated 180 degrees. On the other hand, the upper half of the card, by virtue of the fact that it is being folded as it is being fed to the conveyor, rotates only through approximately 90 degrees. Thus, when the card is deposited upon the conveyor 2 on the appropriate tray, the upper portion of the card in the magazine is placed in a horizontal position upon the tray of the conveyor, and the lower half of the card extends upwardly from the conveyor with the fold edge facing in the direction of conveyor movement from the feeding station to the pressing station.

At this point in the process, an operator places an article to be packaged within the pocket of the horizontally disposed half of the card. As the card is fed forward to the press, a pair of curved guide bars fold the upstanding portion of the card down upon the lower horizontal portion, as best shown in FIGURE 1. The folded and loaded card is conveyed through one intermediate station between loading station and the pressing station and is thereafter brought into the pressing station between the die halves of the press. The die halves each include a central recessed portion for receiving the bubble or pocket of the card. As the die halves close, they close and press the card halves into tight, intimate contact. The dies, having been heated by the plate heaters, heat seal the card under pressure and heat by softening the thermoplastic material that forms the bubble or pocket and which also extends on the inner, folded surfaces of the card in the area surrounding the bubble. It is the material surrounding the 16 bubble, between the folded card surfaces that seals the card. After the required time of the pressing and heating, as controlled by the timer, the press is open, the conveyor advances and, as the conveyor moves around the chain support wheels 59-62 at the end of the machine, the sealed card is deposited in a hopper.

While in the foregoing disclosure, a preferred embodimente of the invention has been disclosed, it will be evident that numerous modifications or alterations may be made therein without departing from the spirit or scope of the invention as set forth in the appended claims.

What is claimed is:

1. In a process of sealing packages that have an apertured display card and a product receiving plastic pocket supported by the card and a product in the pocket, the stops comprising:

(a) carrying a display card from a hopper to a gen erally horizontal surface while simultaneously folding card along a prescored line,

(b) depositing the card on the surface with one folded portion positioned horizontally and another folded portion extending upward,

(c) placing a product in the pocket of one folded portion of the card,

(d) moving the card to a heat sealing station while further folding the upward extending portion toward the horizontal portion,

(e) pressing the two portions together and heat sealing the two portions of the card together.

2. Apparatus for sealing packages having an apertured display card and a product receiving plastic pocket supported by the card, comprising:

(a) a conveyor for supporting and moving display cards along a predetermined path,

(b) means for holding a plurality of cards above the conveyor,

(c) means to transfer cards from the holding means to the conveyor, said means including:

(i) an arm rotatable from a position in engagement with a card held above the conveyor to a position where the card is supported on the conveyor, and

(ii) means on the arm for selectively engaging,

holding and releasing a card,

(d) drive means associated with the conveyor for intermittently moving the conveyor along the predetermined path,

(e) means powered by the drive means for the conveyor for rotating the arm between the said positions in predetermined synchronism with the intermittent movement of the conveyor,

(f) means associated with the transfer means for controlling the arm to selectively engage, hold and release a card in synchronism with the intermittent movement of the conveyor, and

(g) means along the conveyor for pressing and heat sealing the card in synchronism with the intermittent movement of the conveyor.

3. The apparatus of claim 2 wherein the means for intermittently moving the conveyor includes a gear drive that moves the conveyor at a non-uniform speed.

4. The apparatus of claim 3 wherein the gear drive includes a driving gear mounted on a shaft for eccentric rotation with respect to the axis of rotation of the shaft, a driven gear mounted in a second shaft for concentric rotation with respect to the axis of rotation of the second shaft, and an intermediate floating gear mounted on a floating third shaft for concentric rotation with respect to the axis of rotation of the third shaft and meshing with the driving and the driven gears, and pivotal links conmeeting the first and second shafts with the third, floating shaft.

5. In a device for transferring a sheet of material between a stack of such sheets and a support,

(a) an arm. extending transversely of and rotatable about a horizontal axis.

(b) means supporting the arm for rotation about the horizontal axis,

() sheet engaging means carried by the arm adjacent the end thereof and spaced from the longitudinal axis of the arm,

(d) means associated with the supporting means for the arm for pivoting the sheet engaging means about the longitudinal axis of the arm, and

(e) means for rotating the arm support means to rotate the arm about a horizontal axis.

6. Card transfer apparatus which comprises an elongated rotatable bar, means supporting said bar for rotation about a longitudinal axis of the bar, an elongated arm extending transversely from said bar in two diametrically opposite directions, means mounting said arm on said bar for rotation about a longitudinal axis of the arm, two support rods, one extending from each end of said arm transversely thereof, said rods extending from said arm in planes oriented essentially at night angles from each other, and a vacuum cup attached to each of said rods.

7. The apparatus of claim 6 including means for rotating said bar through sequential arcs of 180 degrees in one direction about its longitudinal axis and means associated with said bar and cooperating with said arm to rotate said arm 90 degrees about its longitudinal axis first in one direction when the bar rotates 180 degrees, and then back when the bar rotates another 180 degrees.

8. A method of feeding and folding a card along a prescored line, which comprises:

(a) orienting the card in a generally vertical disposition at a first location with the prescored line horizontal and What will be the outside surface of the folded card facing in a first direction,

(b) engaging the outside surface of the card just beneath the prescored line,

(c) moving the engaged card from the first location in the first direction in which it is facing,

(d) initially and temporarily restraining movement of an upper edge of the card while performing step (c) and (e) thereafter depositing the card while still engaged upon a generally honizontal support with only the portion of the card that was initially above the prescored line in contact with the horizontal support.

9. The method of claim 8 including the step of rotating the portion of the card beneath the prescored line through 180 degrees of rotation as it is moved from the generally vertical disposition to the horizontal support, while rotating the portion of the card above the prescored line through no more than 90 degrees of rotation.

10. In a method of folding a card prescored along a line across the card, the steps comprising: engaging the card on one side only of the prescored line, swinging the engaged side of the card through a semi-circular arc while rotating the engaged side approximately 180 degrees, and retarding movement of the part of the card on the other side of the prescored line so that it rotates through no more than about 90 degrees.

11. Apparatus for folding cards and feeding them to a conveyor which comprises:

(a) support means for holding a plurality of cards 1n a generally upright position above, and extending transversely of, a processing line, and

(b) transfer means for taking the cards, one at a time from the support means and depositing them in a folded condition upon the processing line, said transfer means including:

(i) a pair of spaced, upstanding support bars, one

on each side of the processing line,

(ii) a mounting bar extending between the support bars transversely above the processing line and supported by said bar for rotation about a longitudinal axis of the mounting bar,

(iii) a pair of parallel feeder arms supported by the mounting bar, each one of said pair being spaced from the other transversely of the processing line and each extending from the bar in two opposite directions, each said feeder arms being supported by the mounting bar for rotational movement about its longitudinal axis,

(iv) a vacuum cup mounted at each end of each feeder arm of the pair, each said vacuum cups being mounted on a support arm extending transversely of the longitudinal axis of the respective feeder arm, the two support arms of each feeder arm extending in directions at ninety degrees from each other,

(v) conduit means associated with the transfer means for connecting the vacuum cups to a source of vacuum,

(v) control means on said mounting bar and operatively associated with said conduit means for selectively connecting the conduit means with the vacuum source,

(viii) means, including a gear on each feeder arm and a rack supported by the mounting bar, for rotating the feeder arms about their longitudinal axes,

(viii) control means operatively associated with the mounting bar for moving the rack relative to the mounting bar to selectively rotate the feeder arms about their longitudinal axes, and

(ix) drive means to rotate said mounting bar about its longitudinal axis.

12. In a packaging apparatus, an endless conveyor extending along a predetermined horizontal path; means to drive the conveyor intermittently and with gradual acceleration and deceleration; a plurality of spaced receiving trays on the conveyor for receiving packages to be pressed and heat sealed, said trays including locator means for properly locating a package and having an opening underlying a portion of the package; means above the conveyor for supplying packages to be formed, loaded and heat sealed; feed transfer means for engaging a package from said supplying means, moving said package in an arc to the conveyor, folding the package while it is so moved and depositing it on a tray adjacent said locator means and over said opening; a press mechanism positioned adjacent the conveyor subsequent to the feed transfer mechanism in the direction of conveyor movement between the feed transfer and press mechanism, said press mechanism including upper and lower platens, a plate heater on each platen, a die plate carried by each platen and heated by said plate heater, and means to move said platens toward and away from each other in intermittent cycles; and transmission and control means for driving the conveyor, feed transfer means, and press means in timed relationship to feed a package to the conveyor, to advance a package on the conveyor into and out of the press mechanism, and to open and close the press platens, and to heat seal a package in the press mechanism when the conveyor is stopped.

13. In a packaging machine, a generally horizontal conveyor for receiving and carrying packaging cards; a magazine above the conveyor for supplying cards to be processed; a feed transfer mechanism, including arms rotatable about an axis extending transversely above the conveyor, said arms having vacuum cups, which arms also pivot about their longitudinal axes to engage a card in the magazine with the vacuum cups independently of rotation of the arms about the transverse axis, for carrying a card from the magazine to the conveyor; a press located along the conveyor and havinug two platens, one above and one below the conveyor, for pressing and heat sealing cards carried along the conveyor; drive means to move the conveyor intermittently along a predetermined path, from the feed transfer mechanism to press; means to move the vacuum cups into engagement with a card in the magazine while the conveyor is stopped and the platens are opening; means to then rotate the arms about a transverse axis above the conveyor and to simultaneously advance the conveyor to simultaneously carry one card to the conveyor and feed another card on the conveyor into the press; drive means to operate the press and to begin closing the press as the conveyor feeds a card into the press; means to stop the conveyor and feed transfer mechanism when a card is in position in the press and while the press is closed; and means to control the time duration that the press is closed and to then open the press.

14. In a device for transferring a sheet of material from one location to another, an elongated arm rotatable about an axis transverse to the longitudinal axis of the arm and pivotable about the longitudinal axis; means to support the arm for such rotation and pivoting; a transmission for driving the arm in the said rotation and pivoting movements, said transmission having a constant speed input shaft, a constant speed intermediate shaft and a nonuniform speed, discontinuously rotating output shaft; drive means connected from the discontinuously rotating output shaft to rotate the arm discontinuously about an axis transverse to the longitudinal axis of the arm, and drive means actuated from the constant speed intermediate shaft to pivot the arm about the longitudinal axis only when the output shaft is not rotating.

15. In a packaging machine, a feeder for transferring cards from a supply to a conveyor, a conveyor for receiving the cards and feeding them along a path for processing, a heat sealing press for forming a sealed package from the card, and means for intermittently driving the feeder, conveyor and press and for controlling their operation to feed a card and move the conveyor when the press is open and to stop the feeder and conveyor when the press is closed, and to gradually accelerate and decelerate the feeder, conveyor and press when they are driven.

16. In a packaging machine, an endless conveyor for carrying a card with an article containing pocket in it from a loading station to a heat sealing station, said conveyor comprising two laterally spaced chains extending longitudinally along a conveying path, and a plurality of spaced flexible trays fastened between said chains at spaced locations along the chains said flexible trays having a flat portion in which an opening is provided to accommodate the article containing pocket and to expose at least a portion of the card surrounding the pocket, and also having locator means extending from the tray defining a desired card position on the tray.

17. The machine of claim 16 including a source of cards, and means operated in timed relationship with the conveyor for feeding cards from the source to the flexible trays in a position on the tray defined by the locator means.

18. In an article handling machine having a conveyor and an article feeder for feeding articles to the conveyor, a transmission for operating the conveyor and article feeder, said transmission having two shafts, a first of which rotates through one complete revolution during which time a second of which also rotates through one complete revolution and dwells, means associated with the first of the shafts for controlling the article feeder to engage during the dwell of the second shaft an article to be fed, and means associated with the second of the shafts for operating the article feeder to move articles engage by the feeder to the conveyor and means for simultaneously advancing the conveyor during rotation of the second shaft.

19. In a packaging machine: a horizontal conveyor for receiving cards from a supply and carrying them along a path for processing; a magazine for holding fiat cards having two panels separated by a fold line with the plane of each card extending transversely across the path of the conveyor and inclined at a first angle from the plane of the conveyor; a support bar extending upward from the plane of the conveyor and adjustable in length along a path extending upward from the conveyor at a second angle from the horizontal plane of the conveyor; an arm carried by the support bar for rotation in a vertical plane about a horizontal axis that extends transversely of the conveyor; means carried by the arm to engage a card and to carry the card through degrees of rotation of the arm from the magazine to the conveyor and to thereby locate the center of a lower panel of the card at a predetermined location; means to adjust the effective length of the support bar; and means to adjust the length of the arm carried by the support bar; the relationship of the said first angle and the said second angle relative to the conveyor being such that, notwithstanding adjustment of the effective length of the support bar and the length of said arm to accommodate cards of different sizes, the centers of the lower panels of the cards of different sizes are located at the said predetermined location on the conveyor upon rotation of the arm through 180 degrees from the plane of the card at the magazine, whereby the predetermined location remains the same for different size cards and the conveyor can advance cards the same distance in cycles of movement throughout a range of card sizes.

20. In a process of packaging a product in an apertured display card having a pocket area for receiving the product: feeding cards one after another from a card supply to a conveyor that carries the cards to a location for sealing, folding each card to form two panel portions having flat surfaces spaced apart, loading each card by placing a product between the two spaced panel portions while the card is on the conveyor, moving the loaded cards with the conveyor, closing each loaded card by forcing one panel portion toward the other in response to card movement by the conveyor, and thereafter sealing the two card panel portions of each loaded card together in face-to-face relationship.

References Cited UNITED STATES PATENTS 3,078,769 2/1963 Flynn et al. 9349 X 3,118,262 l/l964 Messick 53184 3,139,712 7/1964 Woskin 5333 3,195,284 7/1965 Crane 53-30 3,261,217 7/1966 Schick 74-393 X WILLIAM W. DYER, JR., Primary Examiner.

GRANVILLE Y. CUSTER, Examiner.

R. L. FARRIS, Assistant Examiner. 

